Weibull Analysis of DPF Failure Events and Reliability of Diesel Particulate Filters Utilizing After-Sales Maintenance Data

Diesel particulate filters (DPFs) are essential tools for controlling pollution emissions. However, some DPFs may encounter failures during operation, thereby posing risks to both the diesel vehicle engine and emission control. Low-quality diesel fuel, due to its higher sulfur content, raises the risk of diesel particulate filter (DPF) becoming inactive. This paper examines the reliability of diesel particulate filters (DPFs) from a leading national vehicle manufacturer, utilizing after-sales maintenance data. Statistical analysis has been conducted on 10,833 vehicles over the years 2018 to 2022. In addition, the records of failures, the root causes of malfunctions, and the factors influencing the failures of these filters have also been investigated. The results indicate that the highest percentage of failures is associated with urban buses, and the least reliable are minibuses. In such a way that, it can be stated that the diesel particulate filters of all minibuses malfunction at least once after 17,000 km, which is significantly lower than the defined threshold of 100,000 km. The main causes of damage to the DPF substrate are leaks in the fuel and lubrication systems. Additionally, laboratory analysis of a passive DPF sample (made up of silicon carbide, using scanning electron microscopy (SEM) detected corrosion within the DPF substrate. The chemical compounds obtained from laboratory studies indicate a high percentage of sulfur (2.28% by weight) in diesel fuel and oil leakage into the diesel particulate filter. Chemical compounds obtained from laboratory studies indicate a high percentage of sulfur (2.28% by weight) in diesel fuel and oil leakage to the diesel particulate filter. This study accurately demonstrates the alignment of results obtained from simulation, reliability assessment, failure root cause analysis, and laboratory analysis.